Documentation Operating Instructions oder... · RULMECA GERMANY GmbH Deutsche Bank Leipzig...

RULMECA GERMANY GmbH Deutsche Bank Leipzig HypoVereinsbank Leipzig Umsatzsteuer ID-Nr.:

Registergericht Stendal HRB 107404 BLZ 860 700 00, Kto-Nr. 600 97 57 BLZ 860 200 86, Kto-Nr. 609 434 945 DE139929199

Geschäftsführer: Tobias Badtke IBAN No: IBAN No: Steuernummer:

Aufsichtsratsvorsitzender: DE 06 8607 0000 0600 9757 00 DE 63 8602 0086 0609 4349 45 117/107/00038

Carsten Spangaard BIC: DEUTDE8LXXX BIC: HYVEDEMM495

RULMECA GERMANY GmbH

Wilslebener Chaussee 12-14 Zschortauer Straße 76 06449 Aschersleben 04129 Leipzig Tel.: +49 (0) 34 73 / 9 56-0 Tel.: +49 (0) 341 / 33 98 98-10 www.rulmeca.com www.rulmeca.com

Documentation Operating Instructions

Edition 12/2016 FB 7-5.4 Rev. 04

Rollers

Rev. 04 : Item 5.4 included / PSV description included Editor: B.Brumme

http://www.rulmeca.com/









Index Page 1. Preface 3 2. Safety 4 3. Technical data / Execution 5 4. Description and operation 6

4.1. Usage characteristics 4.2. Design characteristics of single components

4.2.1. Roller tube 4.2.2. Bearing housing 4.2.3. Roller shaft 4.2.4. Bearings 4.2.5. Seal and securing part

5. Operating procedures 9

5.1 Transport 5.2 Storage 5.3 Installation of roller stations 5.4 Mounting instruction for rollers with breathing hole and weather shields 5.5 Installation of roller garlands

6. Maintenance and inspection 13 7. Application in areas with a explosion class 14

7.1. Maximal surface temperature 7.2. Safety under operation, dust influence 7.3. Safety against mechanical influence 7.4. Prevention against electrostatic discharge 7.5. Prevention and reduction from dangerous dust

8. Repair 16










FB 7-5.4 Rev. 04 – Seite 2

1. Preface With an increasing streamlining of manufacturing and handling processes, reliable conveying equipment components such as idler rollers gain ever more importance in ensuring a high degree of availability of belt conveyors. Bulk goods and cargo need to be handled quickly and efficiently under ever harsher conditions.

RULMECA - rollers and idler roller stationes manufactured by RULMECA GERMANY GmbH are reliable, functional products of high service life made on sophisticated engineering equipment. The idler rollers and their components are designed and dimensioned to suit the specific use. Idler rollers are mainly designed for use:

- as components of rigid idler roller stationes for installation in roller supports, bolted or clamped to the belt frame,

- in articulated idler roller stationes in combination with various suspensions on the belt frame,

- as roller conveyor components for handling cargo;

- as carrying elements in pipe - conveyors. FB 7-5.4 Rev. 04 – Seite 3










2. Safety

Rollers are rotating conveying elements which should be mounted so that the operator is not subjected to any hazard !

However, it cannot be excluded that idler rollers of idler roller garlands fail during operation. Continuous monitoring of rollers, roller stations and idler roller garlands is hence imperative. Intervals for inspections have to be decides from the user side, according the conveying conditions and depend from the expected failures. Any defective idler rollers or garlands shall be replaced immediately, or disengaged through lowerators, if possible.

When stopping the belt conveyor note that hot rollers (heat generation through bearing damage) may constitute a severe fire hazard to stopped rubber conveyor belts. Restart the belt conveyor immediately, if required to avoid fires.

If a roller runs hot and/or there is smoke emanating from the conveyor bring the latter to a controlled stop and fight the heat source using appropriate fire fighting equipment.

Comply with relevant safety regulations and instructions to avoid hazards form unintentional belt restarts.

The belt conveyor manufacturer should provide the relevant safety equipment as specified for the operation of belt conveyors.

FB 7-5.4 Rev. 04 – Seite 4










3. Technical data / design

RULMECA - rollers are supplied with the proven RULMECA sealings. The high quality standard is based on:

• roller tubes acc. to DIN 2458, with tight tolerances, electrically welded; • low balance error steel bearing-houses, welded to the idler roller tube all around; • ball bearing seats calibrated in the bearing-houses fitted so that the ball bearings as

installed have the necessary clearance; • precision deep groove ball bearings acc. to DIN 625, size 62 and 63 with bearing clearance class C3 or C4 resp.; • spherical roller bearings acc. DIN 635, size 213 and 223; • long-term lubrication using high-grade special-purpose grease; • proven sealing system, including: - external sealing including end cap and axial sealing, - multiple labyrinth seal, - internal sealing to keep the grease inside the ball bearing,

to limit the breathing process, and to prevent rust from penetrating into the ball bearing

6204 (PSV/1) 6305/-06/-08

(PSV/3/-5/-7 BCD) 6306/-08/-10 (PSV/5/-7/-9 MCD)

6310/-12 ( HDR )

FB 7-5.4 Rev. 04 – Seite 5










4. Description and operating procedure

Roller for application in belt conveyors

RULMECA rollers- have established themselves over many years and are, depending on the type of connection, suitable for installation in rigid support constructions or for insertion into the framework as garlands. They differ from the standards as set out by VDI2341 regarding single components in accordance with the specific purposes for which they are intended. 4.1. Usage characteristics:

- As part of idler stationes in idler carriers or brackets carrying and reversing tracks in conveyors belts;

- In "garland - form" for assembly into stationes using connecting elements;

- For heavy load-carrying capabilities of the idlers and the assembled stationes;

- For inside or outside use;

- For maintenance-free lasting use;

- For conveying speeds of up to 10 m/s, depending on the diameter of the idler;

- For surrounding temperatures of -20 to +50° C - standard design

- For surrounding temperatures of –45°C ( under – 35°C the conveyor must running without hold continuously, for maintenance service also , under focus of all regulations to safety of work ) to +110° C - special design

The idlers have on common construction which brings together many years of experience. The most important parts are:

- Idler - tube

- Bearing houses

- Idler shaft

- Radial groove bearings

- Sealing block

- Securing elements FB 7-5.4 Rev. 04 – Seite 6










RULMECA roller - design uses a continuous shaft with internal bearing. Lubrication of the rolls is not necessary for the whole period of use due to the guaranteed long-lasting lubrication of the lithium-added grease used. The supporting points of the idlers are sealed, so they can be used in the most varied cases in industry and are well protected from dirt and damp getting in. Rolling resistance lies under the norm set out by DIN 22 112, which, especially with long conveyor belts, is important in determining conveyance chracteristics. Thus, lower operating costs are possible. Full exchangeability of idlers of the same type is guaranteed. 4.2. Design characteristics of the single components:

4.2.1. Roller tube Idler tubes are made of welded precision steel pipe according to DIN 2458. The contact side is chamfered. So the required tolerances for practical use can be guaranteed according to DIN 22112 for turning and VDI 2060, Q 60 for uneven load.

4.2.2. Bearing housing

In accordance with the requirements the bearing housings are made of special deep-drawn quality sheet steel with high accuracy. With the calibrated M7 bearing seat, the roller bearing is guaranteed a firm fit onto the bearing housing. For heavy duty applications the material used is a solid bearing housing, which is measured out according to the measurements of the other parts.

4.2.3. Roller shaft

The roller shafts are made from round steel (bright steel). Rollers for rigid mounting have shafts with flats. The flats by so fit securely into the insertion slits of the idler support of the full length of the support - profil. The idlers for the garland-combination are intended for connecting pieces - chain links.

FB 7-5.4 Rev. 04 – Seite 7










4.2.4. Bearings

The applicable roller bearings of the ranges 62, 63 (ball bearings), 312 and 322 (spherical roller bearings) with the air group C3 and C4 guarantee a high carrying performance of the single roller and of the whole roller station.

4.2.5. Seal and securing parts

In front of and behind the roller bearings, there are special seals made of durable plastic. They ensure that the right amount of grease to provide proper lubrication on the on hand and that the rolling resistance is kept to a minimum on the other hand, keeping the grease inside the bearing mechanism. At the same time, the bearings are kept free from influences from the inside of the roller mechanism such as condensation.

In front of the roller bearing a suitable axial support towards the outside and a labyrinth sealing system is preinstalled components, which controls the intrusion of dust and damp. Selected plastics and their design ensure durability and functionality.

The entry gap in out sealing system was chosen so that rainwater cannot get in if the rolls are tilted up to 70°.

Over 70° tilting outdoor and for idler-cleaning with water-stream, we recommend too use spring-water-protecting-caps on top of the idlers for the protection against water! Corrosion can be a reason for a roller – blocker!

The intrusion of dust is hindered using very narrow gaps. Apart form that, centrifugal force acts against the further intrusion of dust onto the idlers. A further feature of the sealing block is the interaction of large chambers and narrow gaps. With this, the air flow rate due to the "breathing", that is, the equalisation of pressure between inside and out, of the idlers is reduced. So the dust suction effect is reduced.

In order to protect the idlers form mechanical demage during running a stable sheet cover for the whole bearing is advised.

FB 7-5.4 Rev. 04 – Seite 8










5. Operation procedures

Transportation and storage, installation of stations and rollers 5.1. Transport The idlers can be transported in collis or with wooden palettes bundled. Mounted idler-garlands can be transported with wooden sledges, bundled. The collis have to be fastened using 2-core fastening cable. If Load bands are to be used, single core bands are to be fastened on the same direction as the surrounding steel bands loops. While lifting, the package has to be kept balanced.

Do not lift the package by steel loops or by the shaft ends. A fall hazard is possible else. Damaged shaft ends can be a reason for a roller – blocker also.

When transporting with fork - lift truck using wooden pallets. 5.2. Storage

The idlers and their accessories have to be stored so that their function is not impaired.

If they are not properly stored, damp and dust can get into the sealing and therefore into the rollers. An earlier breakdown would be the result. Sunlight (UV-rays), heat and heavy temperature changes promote aging and cracking of rubber and plastic parts.

The parts should be stored indoors and there should be a ground clearance of at least 100 mm. Should these requirements be impossible to meet, the following guidelines apply:

- Parts can be stored in the open for up to 6 months after delivery, without covering up. If the ground underneath is solid, the ground clearance should be at least 100 mm. If the ground is loose, then at least 300 mm.

FB 7-5.4 Rev. 04 – Seite 9










- If the parts have to be stored in the open for more than 6 months, the assemblies or single parts must be water and weather-proofed. The covering has to be carried out to avoid condensation. - The climate and temperature of the storage place or room has to match those in running conditions. (Temperature -20° to 50° C)

The storage should be in secure piles.

Only up to 3 assemblies should be piled on top of each other, so long as the ground underneath is solid and even. On no account pile on soft or uneven ground. The loops have only be loosened on solid and even ground. Thereby is a security against rolling of the rollers placed.

5.3. Installation of roller stations

A differentiation is made between fixed roller stations with and without a roller tilted position. For stations with a tilted position care should be taken to have the tilting position run in the running direction of the conveyor. The roller supports are marked with a little arrow which should point in the conveying direction. Idler roller supports which have a cross hole to take up the idler roller should be installed into the belt frame so that the idler roller is pressed against the angle brackets provided in the conveying direction. The roller shafts should rest uniformly on the brackets and be fixed in place using appropriate fixtures. Use good fixtures to securely mount the complete station onto the belt frame. If idler roller supports with ties of cold or hot welded U-sections are used make the screwed connection on the belt frame so that the U-sections do not deflect. We recommend to use supporting sleeves or washers acc. to DIN 440. For safe seating of the rollers in the support provide the idler roller shafts with flats which should match the jogs of the receivers in the support. If the rollers are to be secured against tripping, mount the locking elements after the rollers were installed, beginning with the centre roller or support centre resp. FB 7-5.4 Rev. 04 – Seite 10










Any additional loads from the belt guide should be considered in designing the idler rollers (cf. VDI 2341), and positively eliminated during installation and operation! A roller overload is dangerous and can induce a prematurely breakdown. Without these loads being adequately considered the maximum admissible angle deviation of the belt at the idler roller of 1 degree should not be exceeded.

5.4 Mounting instruction for rollers with breathing hole and weather shields When the roller was fitted in the carrying roller-support it have to be observe that the one-sided breath hole from the side roller pointed to the middle roller ( middle of the support ). If weather shields have been used, one shield each have to be mounted on the outside from the side roller. The one parted return rollers have to be fitted with weather shields on both sides. For return roller stations in V-troughing the same application is valid like the carrying rollers.

weather shield breath hole conservation of the hollow area

FB 7-5.4 Rev. 04 – Seite 11










5.5. Installation of roller garland stations (garlands)

Use commercially available standardized roller chain links or customized screwed coupling links to assemble the rollers to roller garlands. Roller chain links These are elements of roller chains acc. to DIN 8187. Secure the loose butt straps of the links in place using steel pins. Bend the pin ends by ca. 10 degrees using a socket spanner with slots. Take the pins once only.

Screwed coupling links Insert the loose socket pins through a coupling link butt strap and through the bore of the roller shaft or suspension link resp. Push on the second butt strap from the other end, and secure in place using self-locking nuts acc. to DIN 985. Insert all coupling links of a garland roller station from one and the same side. Suspend the articulated garlands in the supporting structure using hooks, butt straps or customized suspensions (including spring-type ones). The coupling links allow the rollers to move in an vertical direction only. That is why the suspension links are designed so as to allow the station to swing in a horizontal direction. Suspend the garlands in the belt frame so that the loose coupling link butt straps are arranged in the direction opposite to the conveying or direction of belt run. Arrange the nuts of the screwed coupling links in the direction opposite to the direction of belt run. This is to reduce the load acting on the locking and retaining elements. Be sure the garlands are free to move.

Any additional loads from the belt guide should be considered in designing the idler rollers (cf. VDI 2341), and positively eliminated during installation and operation! A roller overload is dangerous and can induce a prematurely breakdown. Without these loads being adequately considered the maximum admissible angle deviation of the belt at the idler roller of 1 degree should not be exceeded. If the garlands will be used in a descending or ascending conveyor line a tilting angle > 2° have to be avoid.

FB 7-5.4 Rev. 04 – Seite 12










6. Maintenance and inspection

The rollers, roller supports and garland stations are maintenance-free.

The bearings of the rollers are permanently lubricated and protected against contamination by seals.

However, continuous monitoring of the rollers and roller garlands is still imperative. (have a look at item 2 – safety )

Immediately replace any defective idler rollers or garlands, or disengage using lowerators.

In case of avoidance of accidents and fire in belt conveyors damaged rollers have to be replaced immediately, resp. to shut down with lowering devices, immediately.

This is specifically necessary if one or several of the following occurs:

- bearing defects and / or abnormal running sound, which announce damages;

- axial locking device fails (roller bodies clearly offset);

- shaft broken (in case of welded shafts);

- roller body - tube damaged or completely worn;

- damage in the welding seam of the roller body or damaged bearing housings, disconnected complete or partially;

- supporting rubber rings worn to cylindrical base or completely damaged;

- coupling link loosened or damaged;

- loosening of screws and clamping devices from supports, brackets and so on

If the user ignore the described damages and don´t replace the damaged parts immediately, potentially consequential losses for the belt or other components of the conveyor system can happen.

Conveying material which droped down from the conveyor and clamped between the rotating roller part and the fix frame, have to be remove immediately.

FB 7-5.4 Rev. 04 – Seite 13










Be sure to avoid any material accumulations that reach into the roller running area. Regularly remove any piling-ups, avoiding material penetrating into the sealing area.

When conveying material was accumulate close to the impact point, belt cleaner resp. deflector systems have to be installed. Conveying material, which stack up between roller and belt (deposit build-up), mainly in the return belt, induce to run out of direction from the conveyor belt. Conveying material falling off in the area of the feeding chute, down from the conveyor belt, have to be prevent with adequate arrangements.

7. Application in areas with a explosion class Rollers as components of belt conveyors was designed in such a way , that in the case of a malfunction the rollers can´t become a ignition source, under normal conveying conditions. 7.1. Maximal surface temperature The rollers can operate without exception in the temperature range according the manufacturer guideline. With the application from deep groove ball bearings acc. DIN 625 and spherical bearings acc. DIN 635 a minimal temperature rise can happen only, as compared with the ambiance. (exluding complete roller blockage or complete damage) 7.2. Safety under operation , dust influence If the rollers were used according to regulations, no flames and hot gases can develop. When such mediums influence to the roller from outside, damages from the rubber rings, seal systems and bearings can happen. On that score rollers can´t run no more after a average and have to be replaced, principally. The operator of the belt conveyor has to ensure that the conveyor system was go into operation when the rollers was free of dust-sedimentation. Over there the rollers have to be not coated or bounded from dust. FB 7-5.4 Rev. 04 – Seite 14










7.3. Safety against mechanical influence To beware friction, extremes of heat or sparking, the metallic parts of the roller don´t have direct contact with the bulk material. A continuously monitoring of the roller operating conditions is necessary, therefore. In areas where bulk material will conveyed with high speed and the contact between roller surface and bulk material induce to sparking, mainly in the return belt , the rollers have to be equipped with rubber rings or complete with rubber coat ( expect conveyors with return belt turning device or pipe conveyors ) . Roller bodies made off stainless steel (metal poor in sparking characteristics) can used alternative.

7.4. Prevention against electrostatic discharge All roller parts was connected permanent metallic-conducting with one another. For rubber and buffer rings a elastomer can be used which have electrical discharge

character. The elastomer which apply in RULMECA - rollers has a specific resistivity R < 109 Ωm. The operator of the belt conveyor is responsible that in areas with an explosion class conveyor-belts able to bleed of have to be used, only. See also TRBS 2153 sect. 3.4. (technical regulation for operating safety – German federal office for worker protection). These belts have to be run over conductive grounded rollers and belt pulleys. Conveyor belts and rollers be subject to restrictions according table 2 TRBS 2153 sect. 3.4. in regards to the speed limit .

Basically the operator of the facility have to ensure , that the electrical charge which the belt can admit, was to bleed of about the rollers or roller garlands , with grounding. Therefore the rollers or garlands have to be connected permanent metallic-conduct with the conveyor steel structure. So an electrical charge can bleed of and a risk from an incentive electrostatic discharge was impossible.

FB 7-5.4 Rev. 04 – Seite 15










7.5. Prevention and reduction from dangerous dust The following systems can be applicable for prevention and reduction from dangerous dust: • Sprinkler systems for wetting of the material • Covering hood for the troughing belt • Covering in the impact areas • Suction in the impact areas • Belt cleaners on the impact point, the return pulley and the return belt • Continuously cleaning of the rollers • Usage from pipe-conveyors The producer or operator from the conveyor has to determine the correct selection and combination from such systems.

8. Repair It is recommended not to perform any repair on the idlers. Replace any defective components to maintain the idler garlands in good condition. Use original parts to ensure good functioning and full load-bearing capacity. Maintain the direction of rotation when removing and inserting idlers. Mark the existing rotational direction prior to removing any idlers.

For maintenance- and repair work use well suited professional staff only! A belt conveyor damage can happen when the realization was incorrect. Averages and fires can not eliminate thereby.

FB 7-5.4 Rev. 04 – Seite 16



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